Variable voltage transformer



P 1953 J. L. BONANNO 2,652,500

VARIABLE VOLTAGE TRANSFORMER Filed Oct. 8. 1949 4 Sheets-Sheet l IN VEN TOR. JflSt'P/l A. Bum/7mm flag ATTORNEY p 1953 I J. L. BONANNO 2,652,500

' VARIABLE VOLTAGE TRANSFORMER Filed Oct. 8, 1949 4 Sheets-Sheet 2 2 .1 .1. T l\ T INVENTOR. JOSEPH Z. fia/vmwa A TTORNE Y Sept. 15, 1953 J. BONANNO VARIABLE VOLTAGE TRANSFORMER 4 Sheets-Sheet 3 Filed Oct. 8, 1949 MNY INVENTOR. Jess/=1, A (Raw/mm W ATTORNEY gum Sept. 15, 1953 J. L. BCSNANNO 2,652,500

VARIABLE VOLTAGE TRANSFORMER JOSPH z. Ema/mo ATTORNEY Patented Sept. 15, 1953 VARIABLE VOLTAGE TRANSFORMER Joseph L. Bonanno, Madison, N. J.) assignor to The Lionel Corporation, New York, N. Y., a

corporation of New York Application October 8, 1949, Serial No. 120,269

17 Claims.

The present invention relates to transformers, and is more particularly directed toward transformers for use with toy railroads and the like having provisions for furnishing a plurality of circuits with independently variable voltages.

In the embodiment to be described herein in detail the device is arranged to deliver to four independent circuits alternating current voltages of a predetermined range.

The variable voltages are taken off by movable contacts, preferably rollers, adapted to traverse exposed surfaces on the secondary. Where four circuits are to be controlled, the four rollers may, according to the present invention, be conveniently mounted on swinging arms, these arms being arranged in pairs on opposite sides of a transformer whose secondary faces extend horizontally in vertical planes. Two contact rollers engage each side face of the secondary and each pair is mounted to one side of the coil for swinging movement about a horizontal axis, preferably below the coil.

A further object of the present invention is to provide transformers for the purpose indicated wherein many of the parts used on the ends of the transformer structure may be duplicates of one another, while other parts are of the same design but left or right handed.

A further object of the present invention is to incorporate into the transformer structure a controller for effecting start-stop-reverse operation of the locomotive and whenever desired the operation of a whistle. In the preferred from of construction two such controls are provided, one on each end of the device and one is connected to one of the four load circuits, while the other is connected to the other of the four load circuits.

A further object of the invention is to provide a transformer with controls of the nature above referred to, wherein all of the wiring connections are accessible when the cover is removed and wherein the parts are arranged for ease of assembly during manufacture, or disassembly for inspection or test.

Other and further objects will appear as the description proceeds.

The accompanying drawings show, for purposes of illustrating the present invention, one embodiment in which the invention may take form, it being understood that the drawings are illustrative of the invention rather than limitingthe same.

In the drawings: a

Figure 1 is a perspective view of the transformer taken from the rear;

Figure 2 is a fragmentary perspective view taken from the front;

Figure 3 is a wiring diagram;

Figures 3a, 3b and 3c illustrate the whistle-reverse controller in three different positions;

Figure 4 is a top plan view, with the cover removed and parts broken away at the right to show interior construction;

Figure 5 is a vertical sectional view on the line 5-5 of Figures 4 and 6;

Figure 6 is a transverse sectional view on the line 6-4; of Figure 4, looking toward the coilcore assembly and cooperative movable contacts;

Figures 7 and 8 are sectional views taken in opposite directions as indicated by the arrows and 88 respectively of Figure 4;

Figure 9 is a fragmentary section on line 9-9 of Figures 4, '7 and 8; and

Figure 10 is a fragmentary view of the whistlereverse switch.

The electrical characteristics of the transformer are fully shown in Figure 3. Here the primary coil, suitable for using -125 volt, 60 cycle alternating current is shown at 2!], the field structure at 2| and the secondary at 22, 23, 24 and 25. The secondary 22 is a fixed secondary adapted to have an output of 8 volts; the secondaries 23 and 24 are compensating windings with an output of approximately 5 volts. The secondary 25 is in the form of an exposed winding, and as indicated at 26 is connected in series with 22. It is capable of developing up to 12 volts so that output voltages can be obtained from it of from 8 to 20 volts.

The other end 21 of secondary winding 22 is connected by wire 28 to a circuit breaker 29 which in turn is connected by wire 30 with strap 3| to which are secured four return binding posts marked U. The circuit breaker is in the common return line and is shunted by a short circuit pilot light 32 and resistor 33.

The secondary coil 25 may be contacted by any or all of four roller contacts which may traverse the entire face of the coil or be moved ofi it to open the circuit. These contacts are marked 34, 35, 35 and 31. Contact rollers 35 and 36 are connected to output binding posts marked B and C by wires 35 and 36, while contact rollers 34 and 31 are connected through wires 38 and 39 with contacts 40 and 4|, pivoted switch arms 42 and 43, contacts 44 and 45 and wires 46 and 41 with output posts A and D, respectively, so that the selected variable secondary voltage may be supplied to A, B, C or D.

The switch arms 42 and 43 are pivoted at 48 and 49 and biased to the position shown by mechanism to be described. When either is moved in the direction of the arrow R (Fig, Set) it opens the circuit at the contact 40 and deenergizes the track. When it is shifted in the direction indicated by the arrow W (Fig. 3b) the movable contact 42 (or 43), before it moves off contact 40 (or 4!), engages contact 50 (or 5|) and then without leaving 44 (or 45) reaches a contact 52 (or 53) (Fig. 30). Contacts 40 and 4| are connected to secondaries 23 and 24 by wires 23' and 24'. The contact 50 (or 5|) is connected to a rectifier 58 (or 51) by wire 56' (or 57), and the rectifier is connected through a resistor 58 (or 59) with contact 52 (or 53). The rectifier is also connected by wire 60 (or 6|) with the other side of compensating winding 23 (or 24).

The binding posts A and D are provided for the purpose of supplying variable voltage to track layouts such as indicated at A and D respectively, and for controlling reverse and whistle mechanism such as shown in my Patent 2,155,343. Such a locomotive is indicated at L, on track layout A. It has a motor with armature 34, field 65, reversing switch 66, indexing mechanism 61 for operating the reversing switch, a relay 63 sensitive to superposed direct current, and relay contact 69 in the circuit of a whistle motor Hi, and a lamp or other load TI. Shifting switch 42 in the direction R opens the circuit to the track. This stops the motor and extinguishes the lights. Releasing the switch 42 restores power to the track. and causes the indexing mechanism 61 to advance the reversing switch to open circuit position so that the train does not move. The next manipulation in direction R starts the motor in the opposite direction. Shifting switch 42 in the direction W brings the secondary winding 23 and rectifier 53 in series with the load circuit A-A' and introduces a direct current component to actuate the relay and blow the whistle.

The binding posts C and B are provided for supplying variable voltages to an accessory load such as lamps C or another track layout such as at B. To control a train on such a track an independent reverse whistle controller such as shown in Patent No. 2,317,727 may be inserted in the circuit as at B". A power on pilot light I2 is connected between points 23 and 28 to show that the transformer is connected to an energized circuit.

The stationary, externally visible parts of the transformer include a generally rectangular sheet metal base I 30, adapted to support the device on a suitable support, a molded insulating body member I! and a cover I02 which meet along a horizontal plane I03. The bod member and cover have wide central portions I04 and I05 and narrowed ends I06 and I01, the latter being arc-shaped about a longitudinal axis I33 slightly below the plane I03, so as to provide a generally box-shaped central portion and two reduced drum-shaped ends I09 and Ill). The body member IIlI carries at the rear the binding posts A, B, C, D and U.

Beyond each of the reduced ends I09 and NB, the transformer carries a long throttle control lever III, a short control knob H2 and at the end a whistle reverse lever H3. The long levers III are connected to movable contact rollers 34 and 31 for controlling voltage to posts A and D respectively, while short control levers IIZ are connected to movable contact rollers 35 and 3G to control voltage to posts 13 and C respectively, and the whistle-reverse levers II3 are connected to contacts 48 and 43 respectively. The control levers I II and H2 turn about the axis IIJB, and have hub portions H4 and H5 provided with voltage markings as indicated in Figure and movable past an indicia ring IIE, provided with corresponding reference marks H401 and II5a. Adjacent the whistle-reverse levers H3, which project up through the notched ends of cover I02, are legends whistle and direction. Hence it is apparent that all circuit controls may 4 be effected by highly realistic mechanism and all wiring is completely enclosed.

The field structure 2| of the wiring diagram is shown structurally at I20. It extends transversel of the body member IOI and is centrally located. It is secured to mounting plates I2I by means of brackets I2Ia, lugs I 2Ib and ears I2Ic. These plates are positioned in the body member I DI by lugs I22, Figure 5, and secured to the base I00 and body member IilI by screws I23. The part I20a of the field structure I20 carries the primary winding 20, and the secondary windings 22, 23 and 24. The upper part I2lb of the field structure I20 carries the secondary winding 25 on an insulating core I23, so that the secondary 25 can have two exposed contact faces I25 and I26 in vertical planes. This secondary is preferably made as described in my Patent No. 2,312,382.

Rearwardly of the exposed faces of the secondary, the insulating core I24 has conducting plates I21 onto which the contact rollers may move. At the front it carries insulating stop lugs I29 Which engage the rollers after they have left the winding.

All the operating parts for controlling output voltages and for the whistle and reverse are alike end for end, except that some of them are made right and left handed. Corresponding reference characters will be used for corresponding parts. They are all carried from interiorly disposed, cored out pedestals I30 at the ends of the bod member II, and provided with upwardly opening bearing seats I (II concentric with axis I08.

The seats I3I in the pedestals receive metal tubes I32 whose inner ends non-rotatably carry arms I33 provided with rollers 36 (or The outer ends of the tubes I32 non-rotatably carry the hub portions II5 for levers II2. Insulating bushings I34 and I35 received in the ends of tubes I32 carry shafts I36 which protrude be"- yond the tubes in both directions. The outer end of each shaft I 36 passes through a central opening I31 in the indicia plate IIfi, a loose washer I38, a split washer I39 (received in an. undercut I39) and is non-rotatably secured to the hub portion II4 of throttle lever III by splines I35 entering slits II4. A clamping spring I36" provides a friction grip and a nut I351! opposite hole II4" makes it possible to attach a screw when it is desired to pull the hub ed the shaft.

To angularly locate the indicia plate H6 and the control handles III and I I2, the body member iIiI carries a pin I (Figure 9) which extends through an arcuate slot I46 in the hub H5 of control arm II2, a hole I41 (or I41) in the indicia plate H6, and enters into the hollow interior of hub II 4 for throttle control handle I I I. The latter is provided with three reinforcing ribs I48a, I48b, I480, and one rib Med. A 70 slot I46 gives the arm Hz the proper swing and a somewhat greater angular spacing between rib I480 and rib I48d gives the arm II! the proper swing. The parts just mentioned are made right and left.

The inner end of shaft I36 carries a contact carrying arm I 4| provided with a roller 31 (or 34). The arm and shaft are secured together by a pin I42. Spring I43 bears against bushing I34 and conducting washer I44 with lug I 44a in notch I442) in the pedestal to hold it against rotation, and holds the latter against arm MI. The split washer I39 bears against the Washer I38 50 that the parts are carried in definite position along the axis of shaft I36. Lugs -I44a are soldered to leads 38 and 39 which connect to contacts 40 and 4I.

The top of each pedestal I is notched as indicated at I60 to receive a contact I6I bearing on top of the tube I32. This contact is connected by wires or 36' to binding post B or C. The contacts I6I are covered by insulating sheet I62 and held in place by plates I63 fastened in place by screws I64 threaded into holes I65 in the pedestals, so that the plates are completely insulated. These plates form the return for the rectifiers.

The plates I63 each carry a Whistle-reverse controller and one carries the power on pilot light 12 while the other carries the short circuit pilot light 32. To carry the Whistle-reverse controller, theplate I63 is provided with brackets I65 to which is secured an insulating plate I61. This plate carries a shaft I68 on which is pivotally mounted the lever II3 above'referred to. The lever is biased to mid-position by a spring I39 whose ends are in slot I69a and I6!!!) in the insulating plate I61 and carries the switch arm 42 (or 43). The stationary plate I61 carries the contacts 40, 44, and 52, arranged so that 44 and 50 (or 45 and 5|) are toward the front of the transformer. The plate I63 also has a downwardly extending bracket I63 on which is mounted the rectifier 56 (or 51) and resistor 58 (or 59). The resistor is wound about the bracket and soldered to it.

The plate I63 carries an upwardly extending yoke I10 with soldering lug I10 for lead (or 6|). This yoke carries an upwardly opening lamp socket Ill. These sockets are opposite holes I12 in the cover I02 and carry lamps 32 and 12 projecting above the covers so as to provide exposed signals. The lamps are provided with colored covers I .13 and I14.

When the cover is off the entire interior of the device is available for inspection, test or repair. The cover is held in place by screws I60 threaded into the sockets I8I at the top of the plates I2I. Alignment of the cover on the body, is assured by lugs I82.

The transformer shown herein is well adapted for controlling from one to four toy railroad circuits and may readily have a rating of 150 or 250 watt depending upon the windings. The entire load may be delivered to any one ofthe four load circuits and as all of the current must necessarily flow through the circuit breaker 29, the device is protected against accidental overload or short circuit. The complete transformer provides a train controller of very realistic appearance, and it is symmetrical. The controls on one end of the transformer unit may be used to control one track circuit with accessories, whistle and train control and the like, while the other end of the transformer may be used for controlling another independent track layout or four track layouts may be controlled, if desired.

Since it is obvious that the invention may be mary coil and at the top thereof a secondary coil having exposed side contact faces extending transversely of the housing, each end of the housing having along a horizontal axis normal to the faces of the secondary coil and below such faces a bearing seat, a tube insulatedly supported in each bearing seat, and carrying a contact movable over the adjacent secondary coil face, a shaft insulatedly supported in each tube and carrying a contact movable over the adjacent coil face, insulated operating handles for the tubes and shafts beyond the ends of the housing, secondary leads connected to the shaft and tube, output binding posts carried by the housing, one of which is connected to the secondary and the others to the secondary leads, and a cover which engage the housing and encloses the coil-core assembly, tubes, shafts, leads and contacts, the handles being beyond the ends of the cover.

2. A transformer as claimed in claim 1, wherein the end portions of the cover and housing are in the cover is open at the ends, the end portions of the cover and housing are narrower than the central portion thereof and the end portions of the cover are surfaces of revolution about said horizontal axis so as to be substantially lower than the central portion, the handles on the tubes closing off the ends of the cover.

5. A transformer as claimed in claim 1, wherein the shafts and housing non-rotatably support an indicia plate between adjacent handles and the handles carry cooperative indicia to indicate the voltage outputs corresponding to handle positions.

6. A transformer as claimed in claim 1, wherein the housing member at its ends carries upwardly extending switch levers each pivoted about a horizontal axis above the first mentioned axis and cooperative fixed and movable contacts in the circuit of an adjacent secondary lead for effecting auxiliary control of said circuit, and the cover is notched to accommodate said switch levers.

'7. A transformer having an elongated upwardly opening housing member, a coil-core assembly secured centrally in the housing member, said assembly having at the bottom thereof a primary coil and at the top thereof a secondary coil having exposed side contact faces extending transversely of the housing, each end of the housing having along a horizontal axis normal to the faces of the secondary coil and below such faces a bearing seat, a tube insulatedly supported in each bearing seat, and carrying a contact movable over the adjacent secondary coil face, a shaft insulatedly supported in each tube and carrying a contact movable over the adjacent coil face, a spring contact bearing on the tube and connected to a secondary lead, a ring carried on each shaft connected to another secondary lead and spring pressed against the shaft carried contact, output binding posts to which the leads are connected, a control handle carried by each tube beyond the end of the housing, a control handle carried by each shaft beyond the corresponding tube carried control handle, and housing carried stops limiting the swing of the control handles.

8. A transformer having an elongated upwardly opening housing member, a coil-core assembly secured centrally in the housing member, said. assembly having at the bottom thereof a primary coil and at the top thereof normally open circuitcompensating secondary windings and a second-- ary coil havin exposed side contact faces ex tending transversely of the housing, each end of the housing having along a horizontal axis nor-- mal to the faces of the secondary coil and below such faces a bearing seat, a tube insulatedly supported in each bearing seat, and carrying a contact movable over the adjacent secondary coil.

face, a shaft insulatedly supported in each tube: and carrying a contact movable over the adjacent coil face, insulated operating handles for thetubes and shafts beyond the ends of the housing, secondary leads connected to the shaft and tube, output binding posts carried by the housing, one: of which is connected to the secondary and the others to the secondary leads, a pedestal cover plate carried by each pedestal, an insulating contact carrying plate carried by each pedestal cover plate and carrying a movable switch arm with a. handle adjacent the tube carried handle, the cover plate carrying contacts cooperable with the switch arm, a rectifier, a shunting resistance, and wiring connections between each set of cover plate carried contacts, with rectifier, and resist-- ance and one of the compensating windings and one of the secondary leads for either opening the circuit to the corresponding binding post or for introducing into said circuit the direct current output of the rectifier without opening said circult.

9. A transformer as claimed in claim 8, having an insulating cover which engages the housing and encloses all said conducting parts.

10. A transformer having an upwardly opening insulating housing with an enlarged central portion and narrower end portions, a coil core assembly mounted with central portion of the housing and having a secondary winding with one end connected to an output terminal and with exposed transversely extending faces, two concentric shafts mounted in each end portion of the housing and insulated from one another, a contact arm secured to each shaft and bearing on the secondary winding, upwardly extending control handles carried by each shaft for operating the respective shafts to move the contacts across the faces of the secondary winding, and output lead connected to the respective shafts.

11. A transformer as claimed in claim 10, having pedestals disposed inwardly of the housing, the pedestals having bearings for the outer shafts, the inner shafts being insulatedly supported on the outer shafts.

12. A transformer as claimed in claim 10, having an insulating cover over the housing and enclosing the coil core assembly, the contacts and leads.

13. A transformer as claimed in claim 10, having in one of the output leads from a shaft at each end a switch with a fixed contact and a movable contact biased to engage the fixed contact and provided with an operating handle adjacent one of the other handles for shifting the movable contact to effect a manual opening of the circuit irrespective of the position of the control handle for said circuit.

14. A transformer as claimed in claim 10, having in one of the output leads from a shaft at each end a switch with a fixed contact and a movable contact biased to engage the fixed contact and provided with an operating handle adjacent one of the other handles for shifting the movable contact to effect a manual opening of the circuit irrespective of the position of the control handle for said circuit, said switch also having two fixed contacts engageable with the movable contact when shifted in the other direction, a supplemental secondary coil, a resistance and a rectifier and connections whereby rectified current may be superimposed on the secondary output current in response to such shifting of the movable contact.

15. A stepdown transformer having a secondary winding with two exposed faces in vertical planes, two contactors bearing on each of the faces, horizontal shafts laterally of the secondary coil faces, each carrying one of the contactors for the face, and two tubular shafts concentric with the first shafts and carrying the other contactors, and handle carried by each of the four shafts for individually shifting the corresponding contactors across the faces of the secondary coil.

16. A transformer having a coil-core assembly with a secondary coil having an exposed face, a support for the coil-core assembly, the support having shaft bearing at right angles to the plane of the coil face and laterally displaced from the coil face, an outer tubular shaft in the shaft bearings, an inner shaft insulatedly carried in the tube, the tube and shaft each carrying at the ends adjacent the coil face a contact arm swingable over the coil face, a tube operating handle having a hub portion, and a shaft operating handle having a hub portion, the support carrying a stop member which extends through an arcuate slot in the first mentioned hub and engages stop members in the second mentioned hub, the second hub having a closed end which covers the stop member.

17. A transformer having a coil-core assembly with a secondary coil having an exposed face, a

support for the coil-core assembly, the support having shaft bearings at right angles to the plane of the coil face and laterally displaced from the coil face, an outer tubular shaft in the shaft bearings, an inner shaft insulatedly carried in the tube, the tube and shaft each carrying at the ends adjacent the coil face a contact arm swingable over the coil face, the shaft bearing an abutment engaging the opposite end of the tube for limiting the movement of the shaft toward the coil, a spring surrounding the shaft and holding the shaft abutment against the tube, handles carried by the shaft and tube for actuating the contact arms, the shaft handle having a hub portion covering the hub portion of the tube operating handle, the support having a stop engageable with the hub portions to limit the movement of the}; handles and concealed by the shaft handle 1 u JOSEPH L. BONANNO,

References Cited in the file of this patent UNITED STATES PATENTS Number 

